Vega VEGAFLEX 66 User manual

Operating Instructions
VEGAFLEX 66
-20 …+250 °C
4…20 mA/HART four-wire
Document ID:
34170
Guided Microwave

Contents
1About this document
1.1Function.................................. 4
1.2Target group .............................. 4
1.3Symbolism used............................ 4
2For your safety
2.1Authorised personnel ........................ 5
2.2Appropriate use ............................ 5
2.3Warning about misuse ....................... 5
2.4General safety instructions . . . . . . . . . . . . . . . . . . . . 5
2.5Safety label on the instrument . . . . . . . . . . . . . . . . . . 6
2.6CE conformity ............................. 6
2.7Fulfillment of NAMUR recommendations . . . . . . . . . . 6
2.8Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
2.9Environmental instructions..................... 6
3Product description
3.1Structure ................................. 7
3.2Principle of operation ........................ 8
3.3Operation................................. 9
3.4Packaging,transport and storage ............... 9
4Mounting
4.1General instructions ......................... 11
4.2Mounting instructions ........................ 12
5Connecting to power supply
5.1Preparing the connection ..................... 17
5.2Connection procedure........................ 18
5.3Wiring plan,double chamber housing . . . . . . . . . . . . 19
6Set up with the indicating and adjustment module PLICSCOM
6.1Short description ........................... 22
6.2Insert indicating and adjustment module. . . . . . . . . . . 22
6.3Adjustment system .......................... 24
6.4Setup steps ............................... 25
6.5Menu schematic............................ 31
6.6Saving the parameter adjustment data. . . . . . . . . . . . 33
7Set up with PACTware and other adjustment programs
7.1Connecting the PC .......................... 34
7.2Parameter adjustment with PACTware . . . . . . . . . . . . 35
7.3Parameter adjustment with AMS™and PDM . . . . . . . 36
7.4Saving the parameter adjustment data. . . . . . . . . . . . 36
8Maintenance and fault rectification
8.1Maintenance .............................. 37
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Contents
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8.2Rectify malfunctions ......................... 37
8.3Exchanging the electronics module . . . . . . . . . . . . . . 39
8.4Software update ............................ 39
8.5Instrument repair ........................... 40
9Dismounting
9.1Dismounting steps .......................... 41
9.2Disposal ................................. 41
10 Supplement
10.1Technical data ............................. 42
10.2Dimensions ............................... 52
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your VEGAFLEX 66,we
offer accessories and replacement parts.The corresponding doc-
umentations are:
l27720 -VEGADIS 61
l30207 -Electronics module VEGAFLEX series 60
l34296 -Protective cover
l31088 -Flanges according to DIN-EN-ASME-JIS-GOST
l30391 -Spacer
VEGAFLEX 66 •4…20 mA/HART four-wire 3
Contents
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1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2Target group
This operating instructions manual is directed to trained qualified
personnel.The contents of this manual should be made available to
these personnel and put into practice by them.
1.3Symbolism used
Information,tip,note
This symbol indicates helpful additional information.
Caution:If this warning is ignored,faults or malfunctions can
result.
Warning:If this warning is ignored,injury to persons and/or serious
damage to the instrument can result.
Danger:If this warning is ignored,serious injury to persons and/or
destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
4VEGAFLEX 66 •4…20 mA/HART four-wire
1About this document
34170-EN-100427

2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
VEGAFLEX 66 is a sensor for continuous level measurement.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
For safety and warranty reasons,any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer.Arbitrary
conversions or modifications are explicitly forbidden.
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to system
components through incorrect mounting or adjustment.
2.4General safety instructions
This is a high-tech instrument requiring the strict observance of
standard regulations and guidelines.The user must take note of the
safety instructions in this operating instructions manual,the country-
specific installation standards as well as all prevailing safety
regulations and accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
During the entire duration of use,the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
VEGAFLEX 66 •4…20 mA/HART four-wire 5
2For your safety
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2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,VEGA provides a confirmation
of successful testing.You can find the CE conformity declaration in the
download area of www.vega.com.
2.7Fulfillment of NAMUR recommendations
With respect to compatibility,the NAMUR recommendation NE 53 is
fulfilled.This applies also to the corresponding indicating and
adjustment components.VEGA instruments are generally upward and
downward compatible.
lSensor software to DTM VEGAFLEX 66
lDTM VEGAFLEX 66 for adjustment software PACTware
lIndicating and adjustment module for sensor software
The parameter adjustment of the basic sensor functions is independ-
ent of the software version.The range of available functions depends
on the respective software version of the individual components.
2.8Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas.These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
2.9Environmental instructions
Protection of the environment is one of our most important duties.That
is why we have introduced an environment management system with
the goal of continuously improving company environmental protection.
The environment management system is certified according to DIN
EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
lChapter "Packaging,transport and storage"
lChapter "Disposal"
6VEGAFLEX 66 •4…20 mA/HART four-wire
2For your safety
34170-EN-100427

3Product description
3.1Structure
The scope of delivery encompasses:
lVEGAFLEX 66 level sensor
lDocumentation
-this operating instructions manual
-Safety Manual 31339 "VEGAFLEX series 60 -4…20 mA/
HART"(optional)
-Operating instructions manual 27835 "Indicating and adjust-
ment module PLICSCOM"(optional)
-Supplementary instructions manual "Plug connector for con-
tinuously measuring sensors"(optional)
-Ex-specific"Safety instructions"(with Ex versions)
-if necessary,further certificates
The VEGAFLEX 66 consists of the components:
lProcess fitting with probe
lHousing with electronics
lHousing cover,optionally available with indicating and adjustment
module
Scope of delivery
Constituent parts
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3Product description
34170-EN-100427

1
2
3
Fig.1:VEGAFLEX 66 -cable version with double chamber housing
1Housing cover with integrated indicating and adjustment module (optional)
2Housing with electronics
3Process fitting
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
lArticle numbers,documentation
lSIL identification (with SIL rating ex works)
With the serial number,you can access the delivery data of the
instrument via www.vega.com,"VEGA Tools"and "serial number
search".In addition to the type label outside,you can also find the
serial number on the inside of the instrument.
3.2Principle of operation
VEGAFLEX 66 is a level sensor with coax,rod or cable probe for
continuous level measurement in products with temperatures between
-20 °Cand +250 °C(-4…+482 °F).
It is designed for industrial use in all areas of process technology and
can be used in liquids.
High frequency microwave pulses are guided along a steel rope or a
rod.Upon reaching the product surface,the microwave pulses are
reflected.The running time is evaluated by the instrument and
outputted as distance.
Type label
Application area
Functional principle
8VEGAFLEX 66 •4…20 mA/HART four-wire
3Product description
34170-EN-100427

Four-wire electronics with separate power supply.
The supply voltage range can differ depending on the instrument
version.
The data for power supply are specified in chapter "Technical data".
Measured value transmission is carried out via the 4…20 mA/HART
output separate from power supply.
The background lighting of the indicating and adjustment module is
powered by the sensor.Acertain level of operating voltage is required
for this.You can find the exact voltage specifications in chapter
"Technical data".
3.3Operation
VEGAFLEX 66 can be adjusted with different adjustment media:
lwith indicating and adjustment module
lwith the suitable VEGA DTM in conjunction with an adjustment
software according to the FDT/DTM standard,e.g.PACTware and
PC
lwith manufacturer-specific adjustment programs AMS™or PDM
lWith a HART handheld
3.4Packaging,transport and storage
Your instrument was protected by packaging during transport.Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environment-
friendly,recyclable cardboard.For special versions,PE foam or PE foil
is also used.Dispose of the packaging material via specialised
recycling companies.
Transport must be carried out under consideration of the notes on the
transport packaging.Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt.Ascertained transit damage or
concealed defects must be appropriately dealt with.
Up to the time of installation,the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated,the packages must be stored only under
the following conditions:
lNot in the open
lDry and dust free
Voltage supply
Packaging
Transport
Transport inspection
Storage
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3Product description
34170-EN-100427

lNot exposed to corrosive media
lProtected against solar radiation
lAvoiding mechanical shock and vibration
lStorage and transport temperature see chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Storage and transport
temperature
10 VEGAFLEX 66 •4…20 mA/HART four-wire
3Product description
34170-EN-100427

4Mounting
4.1General instructions
Make sure that all parts of the instrument exposed to the process,in
particular the sensor element,process seal and process fitting,are
suitable for the existing process conditions.These include above all
the process pressure,process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data"or on the
type label.
Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of an indicating and adjustment
module.The housing can be rotated by 330°without the use of any
tools.You can also install the indicating and adjustment module in four
different positions (each displaced by 90°).
Before beginning the welding work,remove the electronics module
from the sensor.By doing this,you avoid damage to the electronics
through inductive coupling.
With threaded versions,the housing must not be used to screw in the
instrument!Applying tightening forces on the housing can damage its
internal parts.
Use the hexagon for screwing in.
Use the recommended cables (see chapter "Connecting to power
supply")and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry.Rain and condensation water can thus drain off.This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g.through cleaning processes)or
on cooled or heated vessels.
Suitability for the pro-
cess conditions
Mounting position
Welding work
Handling
Moisture
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4Mounting
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Fig.2:Measures against moisture penetration
The reference plane for the measuring range of the sensors is the
sealing surface of the thread or flange.
Keep in mind that a min.distance must be maintained below the
reference plane and possibly also at the end of the probe -
measurement in these areas is not possible (dead band). Keep in mind
that the cable length cannot be used all the way to the end because
measurement in the area of the gravity weight is not possible.These
min.distances (dead bands)are listed in chapter "Technical data".
Keep in mind for the adjustment that the default setting for the
measuring range refers to water.
The process fitting must be sealed if there is gauge or low pressure in
the vessel.Before use,check if the seal material is resistant against
the measured product and the process temperature.
The max.permissible pressure is specified in chapter "Technical data"
or on the type label of the sensor.
4.2Mounting instructions
Mount VEGAFLEX 66 in such a way that the distance to vessel
installations or to the vessel wall is at least 300 mm (12 in).
During operation,the probe must not touch any installations or the
vessel wall.If necessary,fasten the probe end.
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel,as measurement is then possible
down to the lowest point of the bottom.When using the cable version,
Measuring range
Pressure
Mounting position
12 VEGAFLEX 66 •4…20 mA/HART four-wire
4Mounting
34170-EN-100427

keep in mind that measurement down to the tip of the probe is not
possible.The exact value of the min.distance (lower dead band)is
stated in chapter "Technical data".
Fig.3:Vessel with conical bottom
Make sure that the probe is not subjected to strong lateral forces.
Mount VEGAFLEX 66 at a position in the vessel where no
disturbances,e.g.from filling openings,agitators,etc., can occur.
Fig.4:Lateral load
Inflowing medium
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4Mounting
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Excessive system vibration or shocks,e.g.caused by agitators or
turbulence in the vessel (e.g.from fluidisation)can cause the coax
probe of VEGAFLEX 66 to vibrate in resonance.Should a coax probe
of more than 1m(3.281 in)length should be used,you can provide a
suitable support or guy directly above the end of the probe to stabilise
it.
Standpipes or bypass tubes are normally metal tubes with a diameter
of 30 …200 mm (1.18 …7.87 in). In measurement technology such a
tube corresponds to a coax probe.It does not matter if the standpipe is
perforated or slotted for better mixing.Lateral inlets with bypass tubes
also do not influence the measurement.
Measuring probes can be mounted in bypass tubes up to DN 200.
The max.temperature is 250 °C(482 °F).
IfVEGAFLEX 66 is used in standpipes or bypass tubes,contact with
the tube wall should be avoided.We offer spacers as accessories for
fastening the probe in the middle of the tube.
Depending on the tube diameter or tube length,one or several spacers
can be mounted.With cable probes,the cable can also be strained to
avoid contact with the tube.
The max.temperature for the spacers is 250 °C(482 °F).
Aspecial high temperature version of VEGAFLEX 66 with integrated
bypass tube can be used in applications with temperatures up to
400 °C(752 °F).
Keep in mind that buildup can form on the spacers.Strong buildup can
influence the measurement.
Standpipes or bypass
tubes
14 VEGAFLEX 66 •4…20 mA/HART four-wire
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1
Fig.5:Position of the spacer
1Spacer
Note:
Measurement in a standpipe is not recommended for very adhesive
products.
If there is a danger of the probe touching the vessel wall during
operation due to product movements or agitators etc., the measuring
probe should be securely fixed.
In the gravity weight there is a thread (M12), e.g.for a ring bolt
(optional) - (article no.2.27424).
Make sure that the probe cable is not completely taut.Avoid tensile
loads on the cable.
Avoid undefined cable-vessel connections,i.e.the connection must be
either grounded reliably or isolated reliably.Any deviation from this
requirement can lead to measurement errors.
VEGAFLEX 66 should be integrated in the vessel insulation.This
prevents the electronics from strong heating or cooling by temperature
radiation.
Make sure that with heated or cooled vessels the permissible ambient
temperature on the housing is not exceeded.The permissible ambient
temperature is stated in chapter "Technical data"under "Ambient
conditions".
Fixing
Temperature insulation
VEGAFLEX 66 •4…20 mA/HART four-wire 15
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1
2
Fig.6:Vessel with temperature insulation
1Temperature insulation
2Ambient temperature on the housing
16 VEGAFLEX 66 •4…20 mA/HART four-wire
4Mounting
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5Connecting to power supply
5.1Preparing the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltage surges are expected,overvoltage arresters should
be installed
Tip:
We recommend using VEGA overvoltage arresters B63-48 and
ÜSB 62-36G.X.
In hazardous areas you should take note of the appropriate
regulations,conformity and type approval certificates of the sensors
and power supply units.
Supply voltage and current output are carried on separate two-wire
connection cables if reliable separation is required.The supply voltage
range can differ depending on the instrument version.
The data for power supply are specified in chapter "Technical data".
The standard version can be operated with an earth-connected current
output,the Exd version must be operated with a floating output.
This instrument is designed in protection class I.To maintain this
protection class,it is absolutely necessary that the ground conductor
be connected to the internal ground terminal.Take note of the general
installation regulations.
Always connect the instrument to vessel ground (potential equal-
isation)or in case of plastic vessels to the next ground potential.For
this purpose there is a ground terminal on the side of the instrument
housing.
For power supply,an approved installation cable with PE conductor is
necessary.
The 4…20 mAcurrent output is connected with standard two-wire
cable without screen.If electromagnetic interference is expected
which is above the test values of EN 61326 for industrial areas,
screened cable should be used.
Use cable with round cross-section.Acable outer diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.If you are
using cable with a different diameter or cross-section,exchange the
seal or use a suitable cable gland.
Note safety instructions
Take note of sa-
fety instructions
for Ex applica-
tions
Voltage supply
Connection cable
VEGAFLEX 66 •4…20 mA/HART four-wire 17
5Connecting to power supply
34170-EN-100427

If screened cable is necessary,connect the cable screen on both ends
to ground potential.In the sensor,the screen must be connected
directly to the internal ground terminal.The ground terminal on the
outside of the housing must be connected to the potential equalisation
(low impedance).
If potential equalisation currents are expected,the connection on the
processing side must be made via a ceramic capacitor (e.g.1nF,
1500 V). The low frequency potential equalisation currents are thus
suppressed,but the protective effect against high frequency interfer-
ence signals remains.
Take note of the corresponding installation regulations for Ex
applications.In particular,make sure that no potential equalisation
currents flow over the cable screen.In case of grounding on both sides
this can be achieved by the use of a capacitor or a separate potential
equalisation.
With the Exd version,the minus side of the signal output is galvanically
connected to ground via protective diodes.When connecting the
instrument to a grounded PLC,equalising currents can flow in case of
potential differences which can cause malfunctions.Make sure that
there is sufficient potential equalisation from the system side or realise
the connection via switching amplifier.
5.2Connection procedure
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle (current output),
strip approx.1cm (0.4in)insulation from the ends of the individual
wires
4Insert the cable into the sensor through the cable entry
5Lift the opening levers of the terminals with a screwdriver
6Insert the wire ends into the open terminals according to the wiring
plan
7Press down the opening levers of the terminals,you will hear the
terminal spring closing
8Check the hold of the wires in the terminals by lightly pulling on
them
9Connect the screen to the internal ground terminal,connect the
outer ground terminal to potential equalisation
10 Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
11 Connect the lead cable for power supply in the same way
according to the wiring plan,in addition connect the ground
conductor to the inner ground terminal.
Cable screening and
grounding
Installation with
Ex applications
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5Connecting to power supply
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12 Screw the housing cover on
The electrical connection is finished.
Fig.7:Connection steps 5and 6
5.3Wiring plan,double chamber housing
The following illustration apply to non-Ex as well as Ex ia versions.The
Exd version is described in the next subchapter.
VEGAFLEX 66 •4…20 mA/HART four-wire 19
5Connecting to power supply
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1
32
Display
1 2 5 6 7 8
I²C
Fig.8:Electronics compartment,double chamber housing
1Plug connector for VEGACONNECT (I²Cinterface)
2Internal connection cable to the connection compartment
3Terminals for VEGADIS 61
3
1
2
3 41 2
L1 N
4... 20mA
IS
GND
Fig.9:Connection compartment double chamber housing
1Spring-loaded terminals for signal output
2Ground terminal for connection of the ground conductor and screen
3Spring-loaded terminals for voltage supply
Electronics compart-
ment
Connection compart-
ment
20 VEGAFLEX 66 •4…20 mA/HART four-wire
5Connecting to power supply
34170-EN-100427